CN103964866A - Method for preparing lightweight mullite refractory by high-alumina fly ash - Google Patents
Method for preparing lightweight mullite refractory by high-alumina fly ash Download PDFInfo
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Abstract
The invention relates to a method for preparing a lightweight mullite refractory by high-alumina fly ash and relates to the technical fields of solid waste comprehensive utilization and refractories. According to the method, waste from a power plant, namely high-alumina fly ash, is used as a raw material; commercial alumina is added according to the composition design; the mixture is fired and crushed to prepare lightweight mullite aggregate and lightweight fine powder, with different granularities; then silicon dioxide fine powder is additionally added; polystyrene spheres or sawdust is used as a pore-forming agent, aluminate cement is used as a gelling agent, and sodium hexametaphosphate is used as a water reducer; the lightweight mullite refractory is prepared through the processes such as forming by vibration pouring, curing, drying and sintering. The main high-temperature-resistant phase of the lightweight refractory is mullite phase and corundum phase; the lightweight mullite refractory comprises the main chemical constituents: 55.0-70.0 wt% of Al2O3, 25.0-40.0 wt% of SiO2 and 0-5.0 wt% of other impurities. Compared with the prior art, the method has the characteristics of wide raw material source, low production cost, low energy consumption, high mullite content, high performance, long service life, and simple operation in the preparation process; significant economic and environmental benefits can be generated.
Description
Technical field:
The present invention relates to a kind of method of utilizing aluminous fly-ash to prepare mullite light refractory material, relate to solid waste comprehensive utilization, technical field of refractory materials.
Background technology:
Industrial furnace is the main energy consumption equipment in industrial production, and annual energy consumption quantity is very huge, and especially, in the hot procedure in metallurgy, building materials, pottery, glass, chemical industry and dynamo-electric enterprise, the energy consumption of Industrial Stoves can account for 40～70% of total energy consumption.But the thermosteresis of various Industrial Stoves is generally all very large, in most of the cases, their thermo-efficiency is all lower, and energy utilization rate is less than 30%, and having 30～60% calorific loss is to cause by accumulation of heat and the heat radiation of furnace insulation material.In order to improve energy utilization rate, the high performance light heat-insulating material of China's exigence high-quality, to reduce heat lost by radiation and the accumulation of heat loss of large energy, reaches energy-conservation object.
At present, be applied to the aluminosilicate-type refractory fibre of the lagging material large usage quantity of various inner lining of kiln, due to the less (0.14～0.16W/mK of its thermal conductivity, 800 DEG C), saving energy in kiln effect is better, but exist expensive, intensity compared with low, can there is great change and reduce the problems such as its heat-proof quality in structure when 1200 DEG C of high temperature life-time service, generally only has 1/2～1/5 of refractory brick work-ing life.In addition, aluminosilicate-type refractory fibre has carcinogenic possibility to respiratory system, and oneself classifies aluminosilicate refractory fiber as two class carcinogenic substance limit production the European Community.Although China is not yet limited legally to the use of fiber at present, adopt the heat insulating refractory materials of Environmental Safety to substitute the inexorable trend that ceramic fiber is insulating refractory development.
Some refractory materials manufacturers have developed the refractory lining material of some light fire bricks as kiln in succession both at home and abroad, comprising Anorthite light-weight refractory brick and mullite light fire brick.Lime feldspar series light fire brick affects its use temperature and work-ing life because anorthitic intensity is lower with fusing point lower (1550 DEG C), thereby has limited its widespread use.The fusing point high (1850 DEG C) of mullite, intensity is higher, there is high-temperature stable, thermal conductivity is low, thermal expansivity is low, creep-resistant property is good and the excellent properties such as anti-thermal shock good stability, thereby the light fire brick use temperature taking mullite as principal crystalline phase is higher.As the mullite light fire brick that J. P. Morgan & Co. of Britain develops, principal crystalline phase is mullite, and use temperature is from 1430 DEG C to 1540 DEG C, and volume density is minimum is 0.78g/cm
3～0.88g/cm
3, thermal conductivity (600 DEG C) is 0.31～0.36W/mK.Industry is prepared the raw material that mullite light fire brick uses and is mainly higher-grade bauxitic clay.
In recent decades, because the mining authority of bauxitic clay is ineffective, in bauxite ore recovery process, abandon poor a large amount of low-grade bauxites ore deposit that produced owing to adopting richness, be subject to the restriction of traditional aluminium metallurgy technique, substantially effectively not rised in value, it is a large amount of containing Al to utilize and cause
2o
3the waste of mineral wealth.Along with overexploitation and a large amount of outlet of China's bauxitic clay resource, high-quality bauxitic clay mineral wealth day of most of higher-grades is aobvious exhausted.Quality refractory bauxitic clay mineral wealth are the bottleneck problem of exhaustion rapidly, has seriously restricted the Sustainable development of China's refractory industry.
Aluminous fly-ash is the solid waste that coal-burning power plant discharges, and a large amount of flyash discharges is piled up earth's surface and caused tremendous influence to the ecotope of China.Therefore, to the comprehensive utilization of flyash, turning waste into wealth, is to solve China's electrical production environmental pollution, the important means of the contradiction of resource shortage.At present, flyash has obtained application more widely in all departments such as building work, building materials, water conservancy after developing.
Therefore it is significant that, the present invention prepares the efficient utilization of energy-saving and emission-reduction, solid waste resource comprehensive and the environment protection of high performance mullite light refractory material to China's high temperature kiln industry taking power plant's waste aluminous fly-ash as raw material.
Summary of the invention:
The present invention is a kind of method of utilizing aluminous fly-ash to prepare mullite light refractory material, it is characterized in that: the main high temperature resistant thing of this lightweight refractory is mullite phase and corundum phase mutually, and main chemical compositions is: Al
2o
355.0%～70.0wt.%, SiO
225.0～40.0wt.%, other content of impurities is less than 5.0wt.%.
While batching in preparation process of the present invention, add-on and the specification of quality of each raw material are as follows: aluminous fly-ash requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm, add-on 1.0～70.0wt.%; Commercial alumina requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm, add-on 1.0～50.0wt.%; Aluminate cement is the common aluminous refractory cement of CA-70 type, add-on 1.0～8.0wt.%; Fine silica powder requires SiO
2>=98.0wt.%, add-on 2.0wt.%; Sodium hexametaphosphate 99 add-on 0.05～0.3wt.%.
A kind of porous light heat insulating refractory materials that the present invention proposes and preparation method thereof, it is characterized in that: first described method is after raw material aluminous fly-ash and commercial alumina are mixed in described ratio batching, in 1550 DEG C of air atmospheres, burn till and fragmentation makes varigrained mullite lightweight aggregate and lightweight fine powder.Then utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional described ratio, and add account for total batching 0.1～18.0wt.% burn lose pore-forming material (burn lose pore-forming material be wood chip sawdust or polystyrene spheres or the mixture of the two, its particle diameter≤2.0mm) and the tap water of 5.0～15.0wt.% be uniformly mixed together, until aggregate and powder fully mix and have a certain fluidity.The slurry obtaining adopts vibrating casting moulding method to be shaped (also can use mud extruder extrusion molding or manual ramming or castable), and at room temperature natural curing 12～24h of the wet base after shaping is then dried in 50～200 DEG C in dry kiln.Dried adobe is packed in kiln and is burnt till, 1300～1550 DEG C of final firing temperatures, will burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.The main high temperature resistant thing of this lightweight refractory is mullite phase and corundum phase mutually, and main chemical compositions is: Al
2o
355.0%～70.0wt.%, SiO
225.0～40.0wt.%, other content of impurities is less than 5.0wt.%, and correlated performance reaches: volume density≤1.70g/cm
3, line velocity of variation≤4.5%, 700 DEG C of thermal conductivity≤0.70w/m.k, compressive strength>=8.0MPa.
Embodiment:
Below in conjunction with embodiment, technical scheme of the present invention is described further:
Raw material of the present invention and formula are: aluminous fly-ash requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm, add-on 1.0～70.0wt.%; Commercial alumina requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm, add-on 1.0～50.0wt.%; Aluminate cement is the common aluminous refractory cement of CA-70 type, add-on 1.0～8.0wt.%; Fine silica powder requires SiO
2>=98.0wt.%, add-on 2.0wt.%; Sodium hexametaphosphate 99 add-on 0.05～0.25wt.%.
A kind of porous light heat insulating refractory materials that the present invention proposes and preparation method thereof, it is characterized in that: first described method is after raw material aluminous fly-ash and commercial alumina are mixed in described ratio batching, in 1550 DEG C of air atmospheres, burn till and fragmentation makes varigrained mullite lightweight aggregate and lightweight fine powder.Then utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional described ratio, and add account for total batching 0.1～18.0wt.% burn lose pore-forming material (burn lose pore-forming material be wood chip sawdust or polystyrene spheres, its particle diameter≤2.0mm) and the tap water of 5.0～15.0wt.% be uniformly mixed together, until aggregate and powder fully mix and have a certain fluidity.The slurry obtaining adopts vibrating casting moulding method to be shaped (also can use mud extruder extrusion molding or manual ramming or castable), and at room temperature natural curing 12～24h of the wet base after shaping is then dried in 50～200 DEG C in dry kiln.Dried adobe is packed in kiln and is burnt till, 1300～1550 DEG C of final firing temperatures, will burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.
Embodiment 1
Raw material and proportioning:
Aluminous fly-ash add-on is 60.0wt.%, requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm; Commercial alumina add-on 40.0wt.%, requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm; Aluminate cement add-on 6.0wt.%; Fine silica powder add-on 2.0wt.%, requires SiO
2>=98.0wt.%; Sodium hexametaphosphate 99 add-on 0.18wt.%; Burning mistake pore-forming material is wood chip sawdust, and add-on accounts for the 15.0wt.% of above-mentioned total batching, its particle diameter≤2.0mm.
Mullite synthesizing:
First raw material aluminous fly-ash and commercial alumina are mixed according to aforementioned proportion, through ball milling 8h, 150 DEG C of dry 12h and be incubated 4h burn till in 1550 DEG C of air atmospheres, then the technique such as broken and levigate makes varigrained mullite lightweight aggregate and lightweight fine powder.
Prepare mullite light refractory material:
Utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional aforementioned proportion are uniformly mixed; In compound, add burning to lose pore-forming material wood chip sawdust and be uniformly mixed together 10min, then add the tap water of 12.0wt.% to be uniformly mixed together 15min, aggregate and powder are fully mixed and there is certain fluidity; The slurry obtaining adopts vibrating casting moulding method to be shaped.
Base substrate maintenance and dry:
At room temperature natural curing 24h of wet base after shaping, then in dry kiln in 150 DEG C of dry 4h, then dry 8h in 200 DEG C, make water ratio≤3.0% of green compact.
Burn till:
Dried adobe is packed in kiln and burnt till, 1500 DEG C of final firing temperatures, calcining system is: 900 DEG C of insulation 4h, 1300 DEG C of insulation 4h, 1500 DEG C of insulation 5h.
Processing, inspection:
To burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.
The main performance index of resulting product is as follows:
Suitable use temperature: 1400 DEG C; Volume density: 1.68g/cm
3; Line velocity of variation :-4.15% (number representative shrinks); Cold crushing strength: 20.8MPa; 700 DEG C of thermal conductivitys are 0.64W/m.k.
Embodiment 2
Raw material and proportioning:
Aluminous fly-ash add-on is 55.0wt.%, requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm; Commercial alumina add-on 45.0wt.%, requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm; Aluminate cement add-on 8.0wt.%; Fine silica powder add-on 2.0wt.%, requires SiO
2>=98.0wt.%; Sodium hexametaphosphate 99 add-on 0.2wt.%; Burning the 10.0wt.% that loses pore-forming material add-on and account for above-mentioned total batching, is 5.0% polystyrene spheres and 5.0% wood chip sawdust, its particle diameter≤2.0mm.
Mullite synthesizing:
First raw material aluminous fly-ash and commercial alumina are mixed according to aforementioned proportion, through ball milling 8h, 150 DEG C of dry 12h and be incubated 4h burn till in 1550 DEG C of air atmospheres, then the technique such as broken and levigate makes varigrained mullite lightweight aggregate and lightweight fine powder.
Prepare mullite light refractory material:
Utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional aforementioned proportion are uniformly mixed; In compound, add to burn to lose together with pore-forming material (5.0% polystyrene spheres with 5.0% wood chip sawdust) and be uniformly mixed 20min, add again the tap water of 12.0wt.% to be uniformly mixed together 10min, aggregate and powder are fully mixed and there is certain fluidity; The slurry obtaining adopts vibrating casting moulding method to be shaped.
Base substrate maintenance and dry:
At room temperature natural curing 20h of wet base after shaping, then in dry kiln in 150 DEG C of dry 4h, then dry 12h in 200 DEG C, make water ratio≤3.0% of green compact.
Burn till:
Dried adobe is packed in kiln and burnt till, 1500 DEG C of final firing temperatures, calcining system is: 900 DEG C of insulation 4h, 1300 DEG C of insulation 5h, 1500 DEG C of insulation 4h.
Processing, inspection:
To burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.
The main performance index of resulting product is as follows:
Suitable use temperature: 1400 DEG C; Volume density: 1.73g/cm
3; Line velocity of variation :-4.71% (number representative shrinks); Cold crushing strength: 35.6MPa; 700 DEG C of thermal conductivitys are 0.69W/mk.
Embodiment 3
Raw material and proportioning:
Aluminous fly-ash add-on is 58.0wt.%, requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm; Commercial alumina add-on 42.0wt.%, requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm; Aluminate cement add-on 5.0wt.%; Fine silica powder add-on 2.0wt.%, requires SiO
2>=98.0wt.%; Sodium hexametaphosphate 99 add-on 0.18wt.%; The add-on of burning mistake pore-forming material polystyrene spheres accounts for the 14.0wt.% of above-mentioned total batching, its particle diameter≤2.0mm.
Mullite synthesizing:
First raw material aluminous fly-ash and commercial alumina are mixed according to aforementioned proportion, through ball milling 8h, 150 DEG C of dry 12h and be incubated 4h burn till in 1550 DEG C of air atmospheres, then the technique such as broken and levigate makes varigrained mullite lightweight aggregate and lightweight fine powder.
Prepare mullite light refractory material:
Utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional aforementioned proportion are uniformly mixed; In compound, add burning to lose pore-forming material polystyrene spheres and be uniformly mixed together 10min, then add the tap water of 15.0wt.% to be uniformly mixed together 20min, aggregate and powder are fully mixed and there is certain fluidity; The slurry obtaining adopts vibrating casting moulding method to be shaped.
Base substrate maintenance and dry:
At room temperature natural curing 18h of wet base after shaping, then in dry kiln in 150 DEG C of dry 4h, then dry 8h in 200 DEG C, make water ratio≤3.0% of green compact.
Burn till:
Dried adobe is packed in kiln and burnt till, 1450 DEG C of final firing temperatures, calcining system is: 900 DEG C of insulation 4h, 1300 DEG C of insulation 4h, 1450 DEG C of insulation 5h.
Processing, inspection:
To burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.
The main performance index of resulting product is as follows:
Suitable use temperature: 1350 DEG C; Volume density: 1.76g/cm
3; Line velocity of variation :-4.55% (number representative shrinks); Cold crushing strength: 27.8MPa; 700 DEG C of thermal conductivitys are 0.70W/mk.
Claims (3)
1. the present invention is a kind of method of utilizing aluminous fly-ash to prepare mullite light refractory material, it is characterized in that: the main high temperature resistant thing of this lightweight refractory is mullite phase and corundum phase mutually, and main chemical compositions is: Al
2o
355.0%～70.0wt.%, SiO
225.0～40.0wt.%, other content of impurities is less than 5.0wt.%.
2. the method for utilizing aluminous fly-ash to prepare mullite light refractory material as claimed in claim 1, is characterized in that: aluminous fly-ash requires Al
2o
3content>=40.0wt.%, SiO
2content>=40.0wt.%, Fe
2o
3content≤3.0wt.%, TiO
2content≤3.0wt.%, particle diameter is less than 0.1mm, add-on 1.0～70.0wt.%; Commercial alumina requires α-Al
2o
3>=98.0wt.%, particle diameter is less than 0.10mm, add-on 1.0～50.0wt.%; Aluminate cement is the common aluminous refractory cement of CA-70 type, add-on 1.0～8.0wt.%; Fine silica powder requires SiO
2>=98.0wt.%, add-on 2.0wt.%; Sodium hexametaphosphate 99 add-on 0.05～0.3wt.%.
3. the aluminous fly-ash that utilizes of preparing as described in claim 1 and 2 is prepared the method for mullite light refractory material, it is characterized in that: first described method is after raw material aluminous fly-ash and commercial alumina are mixed in described ratio batching, in 1550 DEG C of air atmospheres, burn till and fragmentation makes varigrained mullite lightweight aggregate and lightweight fine powder.Then utilize synthetic aglite and lightweight fine powder, fine silica powder, Sodium hexametaphosphate 99 and the refractory cements of additional described ratio, and add account for total batching 0.1～18.0wt.% burn lose pore-forming material (burn lose pore-forming material be wood chip sawdust or polystyrene spheres, its particle diameter≤2.0mm) and the tap water of 5.0～15.0wt.% be uniformly mixed together, until aggregate and powder fully mix and have a certain fluidity.The slurry obtaining adopts vibrating casting moulding method to be shaped (also can use mud extruder extrusion molding or manual ramming or castable), and at room temperature natural curing 12～24h of the wet base after shaping is then dried in 50～200 DEG C in dry kiln.Dried adobe is packed in kiln and is burnt till, 1300～1550 DEG C of final firing temperatures, will burn till the cooled adobe of kiln discharge on request size cut, obtain mullite light refractory material of the present invention.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201410168057.2A CN103964866A (en) | 2014-04-23 | 2014-04-23 | Method for preparing lightweight mullite refractory by high-alumina fly ash |
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|---|---|---|---|
| CN201410168057.2A CN103964866A (en) | 2014-04-23 | 2014-04-23 | Method for preparing lightweight mullite refractory by high-alumina fly ash |
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ID=51234930
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Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104671811A (en) * | 2015-02-13 | 2015-06-03 | 中国科学院过程工程研究所 | Method for preparing mullite through carrying out two-stage acid treatment on high-alumina fly ash |
| CN110002845A (en) * | 2019-03-11 | 2019-07-12 | 广东金刚新材料有限公司 | A kind of corundum-mullite insulating brick and preparation method thereof |
| CN113511904A (en) * | 2021-04-22 | 2021-10-19 | 武汉科技大学 | Light-weight mullite refractory material and preparation method thereof |
| CN113788688A (en) * | 2021-09-15 | 2021-12-14 | 武汉科技大学 | Lightweight refractory aggregate based on fly ash and preparation method thereof |
| CN114195531A (en) * | 2020-09-18 | 2022-03-18 | 山东鲁阳浩特高技术纤维有限公司 | Anorthite light refractory material with controllable pouring time and preparation method thereof |
| CN115180932A (en) * | 2022-07-06 | 2022-10-14 | 武汉科技大学 | Mullite porous ceramic synthesized in situ based on high-sodium industrial alumina and preparation method thereof |
| CN115611623A (en) * | 2022-09-30 | 2023-01-17 | 安徽华仕新材有限公司 | Preparation method of mullite porous microfiltration membrane support ceramic |
-
2014
- 2014-04-23 CN CN201410168057.2A patent/CN103964866A/en active Pending
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN104671811A (en) * | 2015-02-13 | 2015-06-03 | 中国科学院过程工程研究所 | Method for preparing mullite through carrying out two-stage acid treatment on high-alumina fly ash |
| CN110002845A (en) * | 2019-03-11 | 2019-07-12 | 广东金刚新材料有限公司 | A kind of corundum-mullite insulating brick and preparation method thereof |
| CN114195531A (en) * | 2020-09-18 | 2022-03-18 | 山东鲁阳浩特高技术纤维有限公司 | Anorthite light refractory material with controllable pouring time and preparation method thereof |
| CN114195531B (en) * | 2020-09-18 | 2023-01-31 | 山东鲁阳浩特高技术纤维有限公司 | Anorthite light refractory material with controllable pouring time and preparation method thereof |
| CN113511904A (en) * | 2021-04-22 | 2021-10-19 | 武汉科技大学 | Light-weight mullite refractory material and preparation method thereof |
| CN113511904B (en) * | 2021-04-22 | 2022-06-14 | 武汉科技大学 | Light-weight mullite refractory material and preparation method thereof |
| CN113788688A (en) * | 2021-09-15 | 2021-12-14 | 武汉科技大学 | Lightweight refractory aggregate based on fly ash and preparation method thereof |
| CN113788688B (en) * | 2021-09-15 | 2022-06-14 | 武汉科技大学 | Lightweight refractory aggregate based on fly ash and preparation method thereof |
| CN115180932A (en) * | 2022-07-06 | 2022-10-14 | 武汉科技大学 | Mullite porous ceramic synthesized in situ based on high-sodium industrial alumina and preparation method thereof |
| CN115611623A (en) * | 2022-09-30 | 2023-01-17 | 安徽华仕新材有限公司 | Preparation method of mullite porous microfiltration membrane support ceramic |
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